Elastomer film laminated cushion

ABSTRACT

An elastomer film laminated cushion includes an elastomer having the physical properties of flexibility and compressibilities in the range of flexibilities and compressibilities of stable elastomer block polymer gels. A film is provided for encapsulating the elastomer with the film having physical properties of flexibility to enable uninhibited flexure compression of the elastomer by a user. A compatibilizing layer is provided for laminating the film to an exterior of the elastomer. The compatibilizing layer also has physical properties of flexibility to enable uninhibited flexure and compression of the elastomer by the user.

[0001] The present invention generally relates to cushions and is moreparticularly directed to a cushion utilizing an elastomeric gel.

[0002] Cushions heretofore available have been made from a great numberof materials such as foams and gels. In particular, stable elastomericblock polymer gels such as those described in U.S. Pat. No. 3,676,387have been utilized which are polymer-oil combinations. Elastomeric blockpolymers have been combined with oils in order to control theflexibility and compressibilities of the gels. For example, when anelastomer block polymer, such as described in the hereinabove referencedU.S. Pat. No. 3,676,387, is combined with a non-aromatic paraffinic oillow volatility, an extremely highly elastic material can be obtained.This gel is thermoplastic/thermosetting and is capable of being meltedupon heating for casting in the formation of molded or other articles atroom temperature.

[0003] Unfortunately, these gels, after formation, tend to exude oilover long periods of time. Accordingly, in order to utilize these gelsin an acceptable cushion, they must be encapsulated or covered with amaterial to prevent seepage of oil therefrom, which can cause stainingto any support used for the cushion or provide an uncomfortableoily-like surface if in direct contact with a user.

[0004] Accordingly, such gels have been bonded to fabrics and films inorder to encapsulate the gels. The bonding or lamination of the gel istypically done at high temperatures, for example, about 400° F., andwhen used with very thin-films, such heated contact can causeshriveling, or bubbling of the film, which results in an unattractivefinished product. The use of very thin films is very important in theoverall suitability of the cushion in order to prevent restriction ofthe flexibility and compressibility of the elastomer gel.

[0005] That is, uninhibited elastomer gel properties of flexibility andcompressibility are desired in the final product. Heretofore, filmsutilized to encapsulate the elastomer gels require sufficient thicknessto prevent the hereinabove noted stretching and bubbling of the filmupon formation of the cushion. Unfortunately, such thick films inhibitthe flexural and compressible characteristics of the gel which reducesthe flexural and compressibility characteristics of the completedcushion.

[0006] The present invention is directed to an elastomer film laminatedcushion which maintains the properties of the elastomer gel utilized,while at the same time providing a barrier for oil seepage from theelastomer gel into the environment.

SUMMARY OF THE INVENTION

[0007] An elastomer film laminated cushion in accordance with thepresent invention generally includes an elastomer having the physicalproperties of flexibility and compressibility in the range offlexibilities and compressibilities of stable elastomer block polymergels. The film provides a means for encapsulating the elastomer with thefilm having the physical properties of flexibility to enable uninhibitedflexure and compression of the elastomer by a user.

[0008] Importantly, a compatibilizing layer provides a means forlaminating the film to an exterior of the elastomer. More particularly,the compatibilizing means enables the heat lamination of the elastomerto the film at temperatures up to about 400° F. without shrivelingand/or bubbling of the film. Also, the compatibilizing layer means hasphysical properties of flexibility to enable uninhibited flexure andcompression of the elastomer by a user.

[0009] The physical properties of both the film and the compatibilizinglayer are important in order to enable the cushion to provide desirableflexibility and compressibility of the elastomer, while at the same timepreventing any oil leakage from the cushion.

[0010] More particularly, when the film is formed from a urethane resinand the elastomer is formed from elastomer resin, the compatibilizinglayer means comprises a mixture of the urethane resin and the elastomerresin or a compatible elastomer resin.

[0011] In order to provide desired physical properties of the film andthe compatibilizing layer, the film should have a thickness of betweenabout 1 mil and about 5 mils and the compatibilizing layer should have athickness of between about 10 mils and about 15 mils. With thesethicknesses, the flexibility and compressibility properties of the gelare uninhibited and thus the physical properties of the resultingcushion are substantially the same as those of the elastomer.

[0012] Still more particularly, the compatibilizing layer mixture maycomprise about 25 percent urethane resin and about 75 percent elastomerresin.

[0013] A method in accordance with the present invention for producingan elastomer film laminated cushion generally includes the steps ofproviding a thermosetting elastomer resin and a urethane film.

[0014] A compatibilizing layer is applied on to the film with thecompatibilizing layer comprising a mixture of urethane resin andadditional elastomer resin.

[0015] The elastomer resin is heated to form a gel and thereafterlaminated to the compatibilizing layer at temperatures of up to about400°. A gel forms an elastomeric body having physical properties offlexibility and compressibilities in the range of flexibilities andcompressibilities of stable elastomer block polymer gels.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The present invention may be more clearly understood withreference to the following detailed description in conjunction with theappended drawings, of which:

[0017]FIG. 1 is a perspective view of a typical cushion made inaccordance with the present invention;

[0018]FIG. 2 is a cross sectional view of the cushion shown in FIG. 1taken along the line 2-2 showing a cross section of an elastomerencapsulated by a film with a compatibilizing layer therebetween; and

[0019]FIG. 3 is a representation of the method of producing the cushionin accordance with the present invention.

DETAILED DESCRIPTION

[0020] With reference to FIG. 1 there is shown an elastomer filmlaminated cushion 10 in accordance with the present invention, which, asis more particularly shown in FIG. 2, includes an elastomer 12 and afilm 14 which provides a means for encapsulating the elastomer 12. Ashereinabove noted, encapsulation of the elastomer 12 is important forproviding a barrier to plasticizing oil which may be utilized in theelastomer.

[0021] The elastomer 12 may be of any suitable type such as, forexample, a stable isomeric block polymer gel similar to the geldescribed in U.S. Pat. No. 3,676,387. This patent is incorporatedherewith in its entirety for the purpose of describing a suitable typeof gel for incorporation into the present invention.

[0022] Generally, the gels are of polymer-oil combinations.Specifically, the elastomer 12 has the physical properties offlexibility and compressibility in the range of flexibilities andcompressibilities of the stable elastomer block polymer gels such as setforth in U.S. Pat. No. 3,676,387.

[0023] With reference to FIGS. 2 and 3, the transparent film 14 may beof urethane, or polyurethane film, which encapsulates the elastomer 12.The film 14 thickness as hereinabove noted is preferably between about 1mil and about 5 mils in order to encapsulate the elastomer 12 and have aresiliency which enables uninhibited flexibility and compression of theelastomer 12 by a user's wrist (not shown).

[0024] That is, the film 14 has physical properties of flexibility,because of its thickness, to enable uninhibited flexure and compressionof the elastomer 12 by the user. A film 14 thickness beyond this rangehas not been found to be effective in maintaining the gel-like propertyof the elastomer 12 while providing encapsulation of the elastomer 12.

[0025] Importantly, a compatibilizing layer 16 provides a means forlaminating the film 14 to an exterior 18 of the elastomer 12 attemperatures up to about 400° F. without shriveling and/or bubbling ofthe film 14 during the process.

[0026] In order to maintain the flexibility and compressibilityproperties of the elastomer 12, the compatibilizing layer 16 must havephysical properties of flexibility to enable such uninhibited flexureand compression of the elastomer by the user. The flexibility propertiesof both the film 14 and the compatibilizing layer 16 are effected whenthe film 14 is made from a urethane film having a thickness of betweenabout 1 mil and about 5 mils.

[0027] The compatibilizing layer is a mixture of urethane resin andelastomer resin, preferably about 25 percent urethane resin and about 75percent elastomer resin. The urethane and elastomer resins are heated toa lower temperature than about 400° F. and applied to the film 14 in aconventional manner.

[0028] Thereafter, as is illustrated in FIG. 3, the elastomer 12 isapplied to the compatibilizing layer 16 and the film 14 is sealed to anunderside 20 of the elastomer 12 as illustrated by the arrows 22 in FIG.3.

[0029] The basic process of forming the cushion 10 may be through theprocess set forth in U.S. Pat. No. 5,679,193 entitled, METHOD OFMANUFACTURING A GEL CUSHION; U.S. Pat. No. 5,756,184 entitled, GELCUSHION; and in U.S. patent application Ser. No. 08/856,775 filed May15, 1997, entitled, CUSHION MANUFACTURING METHOD. Both of thesereferenced patents and the application are incorporated herewith intheir entirety by this reference thereto, for illustrating the manner inwhich the gel cushion in accordance with the present invention may bemanufactured.

[0030] An additional compatibilizing layer 26 may be applied to anunderside 28 of the cushion 10 for the purpose of obtaining a gripybottom for the cushion 10. Since the layer, which is also formed from amixture of urethane resin and elastomer resin, is rubbery, somewhat likethe gel 12, it provides a non-slip bottom texture similar to neopreneproducts on the market. If the film 14 is not sealed to the bottom 20 ofthe elastomer, the layer 26, because of its urethane content, provides abarrier to prevent the leakage of oil from the elastomer 12 onto asupporting surface, not shown.

[0031] Although there has been hereinabove described an elastomer filmlaminated cushion in accordance with the present invention, for thepurpose of illustrating the manner in which the invention may be used toadvantage, it will be appreciated that the invention is not limitedthereto. Accordingly, any and all modifications, variations orequivalent arrangements which may occur to those skilled in the art,should be considered to be within the scope of the invention as definedin the appended claims.

What is claimed is:
 1. An elastomer film laminated cushion comprising:an elastomer having the physical properties of flexibility andcompressibility in the range of flexibilities and compressibilities ofstable elastomeric block polymer gels; film means for encapsulating saidelastomer, said film means having physical properties of flexibility toenable uninhibited flexure and compression of said elastomer by a user;and compatibilizing layer means for laminating said film means to anexterior of said elastomer, said compatibilizing layer means havingphysical properties of flexibility to enable uninhibited flexure andcompression of said elastomer by the user.
 2. The cushion according toclaim 1 wherein said film means is formed from a urethane resin, saidelastomer is formed from an elastomer resin and said compatibilizinglayer means comprises a mixture of urethane resin and elastomer resin.3. The cushion according to claim 1 wherein said film means is formedfrom a urethane resin, said elastomer is formed from an elastomer resinand said compatibilizing layer means comprises a mixture of urethaneresin and elastomer resin.
 4. The cushion according to claim 2 whereinsaid mixture comprises about 25 percent urethane resin and about 75percent elastomer resin.
 5. The cushion according to claim 4 whereinsaid film means has a thickness of between about 1 mil and about 5 mils.6. The cushion according to claim 5 wherein said compatibilizing layermeans has a thickness of between about 10 mils and about 15 mils.
 7. Thecushion according to claim 6 wherein said elastomer is a stableelastomeric block polymer gel-oil composition.
 8. The cushion accordingto claim 7 wherein said film means is sealed around a cushion exteriorto prevent oil leakage from the gel-oil composition.
 9. An elastomerfilm laminated cushion comprising: an elastomer having the physicalproperties of flexibility and compressibility in the range offlexibilities and compressibilities of stable elastomer block polymergels; film means disposed around said elastomer, said film means havingphysical properties of flexibility to enable uninhibited flexure andcompression of said elastomer by a user; and compatibilizing means forenabling heat laminating said elastomer to said film means attemperatures up to about 400° F. without shriveling and bubbling saidfilm means, said compatibilizing means having physical properties offlexibility to enable uninhibited flexure and compression of saidelastomer by the user.
 10. The cushion according to claim 9 wherein saidfilm means is formed from a urethane resin, said elastomer is formedfrom an elastomer resin and said compatibilizing means comprises amixture of urethane resin and elastomer resin.
 11. The cushion accordingto claim 9 wherein said film means is formed from a urethane resin, saidelastomer is formed from an elastomer resin and said compatibilizinglayer means comprises a mixture of urethane resin and elastomer resin.12. The cushion according to claim 10 wherein said mixture comprisesabout 25 percent urethane resin and about 75 percent elastomer resin.13. The cushion according to claim 12 wherein said film means has athickness of between about 1 mil and about 5 mils.
 14. The cushionaccording to claim 13 wherein said compatibilizing means comprises alayer having a thickness of between about 10 mils and about 15 mils. 15.The cushion according to claim 14 wherein said elastomer is a stableelastomeric block polymer gel-oil composition.
 16. The cushion accordingto claim 15 wherein said film means is sealed around a cushion exteriorto prevent oil leakage from the gel-oil composition.
 17. A method forproducing an elastomeric film laminated cushion comprising the steps of:providing thermosetting elastomer resin; providing a urethane film;applying to the film a compatibilizing layer onto the film, saidcompatibilizing layer comprising a mixture of urethane resin andadditional elastomer resin; heating the elastomer resin to form a gel;and laminating the gel to said compatibilizing layer at a temperature ofup to about 400° F., said gel forming an elastomeric body having thephysical properties of flexibility and compressibility in the range offlexibilities and compressibilities of stable elastomeric block polymergels.
 18. The method according to claim 16 further comprising the stepsof sealing the film means together around the gel in order toencapsulate the gel.